Disassembly

Special Tools:

1. Set the transmission on a work bench.





2. Remove the case cover.
1 Remove the case cover bolts.
2 Remove the case cover.





3. Use Seal Remover to remove the extension housing seal.





4. Remove the extension housing.
1 Remove the bolts.
2 Remove the extension housing.





5. Slide the first/second and third/fourth synchronizer sleeves forward to lock the transmission into first and third gears.





6. Remove and discard the countershaft locknut.





7. Remove the (A) countershaft rear bearing and (B) countershaft rear bearing thrust washer.





8. Use Mainshaft Locknut Wrench to remove and discard the output shaft rear bearing lock nut.





9. Remove the bolt.





10. Remove the reverse idler gear and bushing.





11. Use (A) Remover/Replacer Tube, (B) TOD Forcing Screw and (C) Bearing Puller to remove the (D) output shaft rear bearing.





12. Remove the output shaft (A) reverse gear and (B) bushing.





13. Remove the spacer or sleeve.





14. Remove the (A) countershaft reverse gear, the (B) two countershaft reverse gear bearings, and the (C) reverse synchronizer blocking ring.





15. Remove the countershaft split washer.





16. Remove the fifth/reverse shift rail bolt.





17. Remove the fifth/reverse (A) synchronizer, (B) gear shifter fork, and (C) reverse gear shift rail as an assembly.





18. Remove the countershaft fifth gear synchronizer blocking ring.





19. Remove the (A) fifth and reverse shift lever retaining ring and the (B) fifth and reverse shift lever.





20. Remove the bolt.
- Slide shaft out of case.





21. Remove the countershaft fifth speed gear.





22. Remove the (A) countershaft fifth speed gear split bearing and (B) race.





23. Remove the output shaft fifth speed gear.





24. Remove the rear bearing retainer.
1 Remove the retainer bolts.
2 Remove the bearing retainer.





25. Remove the bolts.





26. Remove the main drive gear bearing retainer.
1 Install Front Cover Removing Bolt Set into the slave cylinder bolt locations.
2 Remove the main drive gear bearing retainer.
- Alternately tighten the bolts until the bearing retainer can be removed by hand.





27. Remove the (B) fluid baffle, the (A) input bearing shim, and the (C) countershaft bearing shim.





28. Remove the fluid passage bolt.





29. Remove the fluid passage.





30. Remove the input shaft front bearing race.





31. Remove the output shaft center bearing race.





32. Separate the (A) input shaft and the (B) output shaft.





33. Remove the output shaft.





34. Remove the input shaft.





35. Remove the countershaft cluster gear.





36. Inspect the countershaft cluster gear for damage.